Foldable box



April 1951 A. J. GROSSNIKLAUS 2,549,682

FOLDABLE BOX Filed Aug. 15, 1946 4 Sheets-Sheet 2 INVENTOR. fllz 08 JGmsszzz'filaas ATTORNEYS April 1951 A. J. GROSSNIKLAUS 2,549,682

FOLDABLE BOX V Filed Aug. 15, 1946 4 Sheets-Sheet 3 Fig.4 16a g I 25llmllh u 3 "h.

[N VEN TOR.

B filice Ja'rasszziklaus W ATTORNEYS April 1953 A. J. GROSSNIKLAUS2,549,682

FOLDABLE BOX Filed Aug. 15, 1946 4'Sheets-Sheet 4 E IO M 52 l 5 G O VINVENTOR.

fllzbeJG'rossmZlazzs BY ATTORW'EYS Patented Apr. 17, 1951 UNITED STATESPATENT OFFICE 3 Claims.

The invention relates generally to foldable paper box containers adaptedto be shipped in flat folded condition to a fabricator or packer whounfolds or expands and assembles the containers for packing his producttherein, and this application is a continuation in part of my copendingapplication Serial No. 657,528, filed March 27, 1946, and entitledFoldable Box and Method of Assembling Same.

More particularly, the invention relates to a foldable paper boxcontainer adapted, with 'a grease-proof liner, to serve as a mold intowhich melted processed cheese or other moldable products can be pouredwhile hot and allowed to solidify, after which the box liner can beclosed to serve as a finished package ready for shipment and sale.

Because the bottom surface of the molded cheese as poured is smooth, itis desirable that the box he so constructed that the top of the box aspoured becomes the bottom of the package when closed, so that if the topof the box is transparent the user will first see the smooth surface ofthe cheese when purchasing the package.

A prior foldable paper box construction for this purpose includessimilar tray members compr sing the top and bottom walls and telescopedover a relatively stiff foldable collar forming the side walls of thebox. In order to assemble this construction for receiving and moldingthe hot cheese, the collar is first unfolded or expanded and held in arectangular shape, then one of the trays is unfolded and telescoped overthe collar, and then the assembled collar and tray is telescoped overthe grease-proof liner or envelope while the latter is expanded and heldby suitable means in a box-like or parallelepipedal shape.

While said prior construction serves satisfactorily as a. moldingreceptacle when the collar and one tray are telescopically assembled anda liner positioned therein, a substantial amount of time is requiredfor. this initial assembly operation before the liner can be expandedand telescoped therein. Accordingly, a relatively large number ofcollars and trays must be assembled in advance of the liner expand ngoperation, because the collar and tray assemblies can be telescoped overthe expanded liner more quickly than they can be assembled.Consequently, large stacks of the collar and tray assemblies areprepared in advance, which requires excessive time, and the stackedtrays, occupy a large amount of valuable space which would otherwise beused for other processing or packing operations.

Accordingly, it is a general object of the present invention to providea novel foldable or collapsible paper box for containing processedcheese and other moldable products, which box possesses all of theadvantages of prior constructions and at the same time overcomes theirdisadvantages.

More specifically, it is an object of the present invention to provide afoldable or collapsible box which is adapted to be packed and shippedflat, and which is rapidly expanded and assembled in a form ready forreceiving hot melted cheese.

Another object is to provide a novel collapsible box having only onepart which requires unfolding when expanding and assembling the box inreadiness to receive hot melted cheese, thus materially reducing thetime required for the assembling operation.

In order that the novel col apsible box be made economically andpractically, it is highly desirable that it be cut from flat paperstock, preferably in one piece, and then quickly formed, by folding andgluing, into the rectangular collapsible or foldable box of the presentinvention.

It is therefore another object of the present invention to provide asimple and improved method of making the novel collapsible box from asingle sheet of flat paper stock.

A further object is to provide a novel collapsible box which is soconstructed and arranged that it can be expanded'and assembled rapidlywith a grease-proof liner positioned therein, without requiring apreparatory assembly step.

Another object is to provide a novel collapsible box and an improvedmethod of assembling the same'in condition for receiving and molding hotcheese, whereby a saving of time and work ing space is effected.

A still further object is to provide a novel collapsible box which isadapted to be expanded from fiat condition and assembled with agreaseproof liner therein'as a continuous operation, so

as to materially-reduce the working space required for stacking boxparts prior to inserting the liners therein.

Finally, it is anobject of the present invention to provide a novel andimproved collapsible box,- a novel and improved method of making-thesame, and a noveland improved method of assembling'said box so as toprovide a molding eceptacle and finished package for processed cheese orother molded products.

These and other objects are accomplished by the parts, constructions,arrangements, combinations, methods and method steps, which comprise thepresent invention, the nature-of which is set forth in the followinggeneral statements, a preferred embodiment of which is set forth in thefollowing description and illustrated in the accompanying drawings andwhich is particu' larly and distinctly pointed out and set forth in theappended claims forming partfhereof.

In general terms, the novel collapsible box of I fits under the flangesto form the bottom wall of the box when the cheese is poured and the topwall when the package is finished. A foldable tray or cover member isadapted when expanded or unfolded to telescope over the other end of thebox to form the bottom wall of the finished package.

In general terms, the novel method of making the collapsible box of thepresent invention preferably includes cutting from a flat paper sheet ablank having a central rectangular opening with opposing wall portionsextending laterally from all four sides of said opening, scoring saidwall portions to provide fodable flanges defining said opening andfoldable flaps adjoining said flanges, then folding the flaps accordionfashion and gluing the flap portions upon themselves to form side wallsextending angular-1y from said flanges, and then overlapping and gluingthe ends of one pair of opposing side walls onto adjoining walls tofoldably connect all the side walls for forming a rectangular box whenexpanded.

In general terms, the novel method of assem bling the collapsible box ofthe present invention preferably includes expanding a grease-proof linerwith one side open, and holding it in expanded position with the openside down, placing the flat sheet which is to form the bottom wall ofthe box on top of said liner while the liner is held in such position,then telescoping the novel collapsible box in inverted expandedcondition over said flat sheet and liner to engage the flanges of saidbox over the margin of said flat sheet,

' and then inverting the assembly of the box, fiat sheet insert andliner with the open side of the liner uppermost in readiness to receivehot melted cheese.

Referring to the drawings in which a preferred embodiment of theinvention is shown by way of example;

Figure 1 is a p an view of the fiat blank cut from a single sheet ofpaper for forming the novel collapsible box, the scored fold lines beingindicated in dash lines thereon;

Fig. 2 is a perspective view showing the side wall portions of the boxpartially folded in accordion fashion angularly to the flanges definingthe central rectangu ar opening;

Fig. 3 is a similar view showing the novel box almost completely foldedto rectangular shape, with the end portions of one pair of opposing sidewalls turned inwardly so as to overlap the adjoining side walls;

Fig. 4 is a perspective view of the novel collapsible box in invertedposition and partially folded to fiat condition for shipment;

Fig. 5 is a perspective view of the tray or cover which is adapted totelescope over the box and form the bottom wall of the finished package,said cover being shown in fiat folded condition; a Fig. 6 isa'perspective view of the flat sheet insert which forms the bottom wallof the box when the cheese is. poured and the top wall of the finishedpackage;

Fig. '7 is a perspective view of the novel col-. aps o i u fo d d rxpand d posit on. being inverted with respect to Fig. 3;

Fig. 8 is a perspective view of the tray or cover of Fig. 5 whenexpanded to rectangular form for telescoping over the open end of thecollapsible box;

Fig. 9 is a fragmentary sectional view showing the forming apparatus forexpanding the greaseproof liner into the box-shape suitable for in- Bilsertio in the novel collapsible box when expanded, the expandingapparatus being shown in collapsed position with a liner thereon;

Fig. 10 is a fragmentary View similar to Fig. 6 showing the formingapparatus holding a liner in expanded position and the flat sheet insertof the box positioned on top thereof;

Fig. 11 is an enlarged similar view showing the novel collapsible boxtelescoped in inverted position over the liner and fiat sheet insert toform the sub-assembly which serves as a molding receptacle, for the hotmelted cheese; and

Fig. 12 is a perspective view of the subassembly in upright position inreadiness for receiving the hot melted cheese.

Similar numeralsrefer to similar parts throughout the drawing.

The novel collapsible box and its cover and flat sheet insert are shownin substantially flat po: sition in Figs. 4, 5 and 6 respectively, inthe condition in which they are received from the box manufacturer. Thenovel box is indicated generally at ID in Fig. 4 and is shown folded toapproach flat folded position. The cover which forms the bottom of thefinished package is in-. dicated generally at I l in Fig. 5 and the flatsheet insert which forms the top wall of the finished package isindicated generally at. l2 in Fig. 6. These parts are all made of fiatpaper stock and the parts it and H are properly cut and scored so thateach of them will fold into a flat condition for shipping. Figs. '7 and8 show the box Ill and cover Ii in unfolded or expanded con-. ditionready for assembly.

Figs. 1, 2 and 3 illustrate the novel method of making the collapsiblebox it from a single blank which is cut in one piece from flat paperstock and properly slit and scored for being folded into the rectangularcollapsible box of the present invention.

The paper blank shown in Fig. 1 is cut to have a rectangular opening Ovwith opposing wall por-. tions l3 extending laterally from the longsides of the opening and opposing wall portions I4 extending laterallyfrom the short sides of the opening. Score lines i5 are made in usualfashion on the wall portions l3 adjacent to and parallel with the longsides of the opening 0, and similar score lines iii are made on the wallpor.- tions i4 adjacent to and parallel with the short sides of therectangular opening 0. The score lines It and I6 form a rectangle whichdefines one end of the novel box after the same has formed, and theflange portions 15a and Ilia between said score lines l5 and I6 and theopening 0 become the bottom wall flanges of the box as shown in Fig. 7which support the margin of the flat sheet l2 when it is insertedtherein.

As shown in Fig. 1, the wall portions M are separated from the wallportions l5 by slitting the blank from the ends of each of the scorelines it outwardly along extensions of said score lines as indicated atH. Also, the flange portions l5a and 65a are separated at two diagonallyopposite corners from the adjoining flange portions by slits lg, and areprovided at the other two diagonally opposite corners with scored foldlines indicated at 28a, for a purpose to be hereinafter described.

Each of the wall portions I3 is scored along lines L and L parallel tothe long sides of open, ins 0 to provide the identical adjoining flapportions 19 and the outer flap portion 28 having the same length butnarrower width. Each of the opposing walls [4 is scored along lines S.nd, S

parallel with the short sides of the opening to form identical adjoiningflap portions 2| and an outer flap 22 having a length equal to the scorelines I6 and a width equal to that of flaps 20. Score lines 23 are alsoprovided in the walls I4 as extensions of the score lines I5 andconnecting with the side edges of the outer fiap portions 22.

Referring to Figs. 2 and 3, in making the novel box I 0 from the sheetblank shown in Fig. 1, the side walls I3 and M are folded upwardly alongthe score lines I5 and I6 respec tively, and each of the side walls I3is folded along the parallel score lines L and L thereof in accordionfashion to form the adjoining flap portions I9 and the outer flapportion 20, in the manner indicated in Fig. 2. Similarly, the side wallsI4 are folded accordion fashion along score lines S and S to form theadjoining flap portions 2| and the outer flaps 22 connected thereto.Prior to or during the folding operations, the contiguous surfaces ofthe flaps I9 and 2B and the flaps 2| and 22 are coated with I glue or asuitable adhesive, so that the flaps become the several plies of theflat side walls I3 and. I4

' respectively of the box I0, and the outer flaps 20 and 22 form anoffset or shoulder X'extending around all four sides of the box, sothat-- when the cover II is applied to the box, it will fit On or abutthe offset.

If the outer flaps 20 and 22 do not provide a shoulder or offset ofsuflicient thickness because the paper stock used is relatively thin,additional thickness may be obtained by adding extensions of the samesize to the flaps 20 and 22 in the blank, and connecting the extensionsto the flaps by fold lines at their outer edges so that the extensionscan be folded against the flaps, thereby doubling the thickness of theshoulder on the finished box.

After the flap portions of the side walls I3 and I4 have been folded inthe manner indicated in Fig. 2, the end portions of the side walls I4are folded inwardly about the score lines 23 to form the inner two-plyflaps 24 whiohunderlap the inner surfaces of the side walls I3 and areglued thereto to stifien the same. As is apparent from Fig. 3, thelengths of the inwardly folding twoply flaps 24 are such that when thebox is completed the inner ends 25 of the flaps will abut to form asmooth flush surface along opposite sides of the box.

Accordingly, after the side walls have been folded as'indicated in Figs.2 and 3 with the contiguous surfaces of the flaps glued together, theyform the rectangular box shown in Fig. 7. The purpose of diagonallyslitting the flanges I5a and lea at I8 at two diagonally oppositecorners of the box, and scoring the other two diagonally oppositecorners at I8a, is to allow folding the finished box I 0 to a fiatcondition for shipping, in the manner indicated in Fig. 4. When the box.is folded to the position of Fig. 4, the flaps I5a wall of the finishedpackage, is cut accurately so that it will fit tightly within the sidewens I3 and I4 to hold the box in rectangular form, v

and at the same time will engage the undersides of the flaps I5a andIlia so that they support the sheet in position to form the bottom wallof the box. 7 The cover II is preferably made of a'single sheet ofpaper, and as shown in Fig. 8, includes side walls 26 and 21 and abottom wall 28. The side walls 21 may have flaps 29 which overlap theside walls 26 and are preferably glued thereto, and the side wallportions 21 are preferably scored along lines 39 so as to readily foldinto fiat condition in the manner indicated in Fig. 5. The dimensions ofthe cover II are such that when unfolded or expanded to the rectangularshape shown in Fig. 5, it will telescope with a close fit over the sidewalls I3 and I4 of the box and substantially abut the shoulders X formedthereon by the outer flaps 20 and 22.

The grease-proof envelope vor liner which is utilized is preferably of aplastic material such as heavy cellophane, and may be obtained in fiatfoldedcondition from the manufacturer of such materials. In order toplace the liners in open rectangular position in the boxes in readinessfor receiving the hot melted cheese, as part of a continuous and rapidoperation, it is necessary to provide some sort of mechanism for quicklyexpanding the liner envelopes into proper rectangular shape. A suitablemechanism is shown by way of example in Figs. 9, 10 and 11, andpreferably includes a, pair of rectangular die blocks 32 which aremounted on a table top T for expanding movement away from each other. Asshown, the die blocks 32 may be pivotally connected at their inner endsto links 33 which are pivoted to the'upper end of an actuating rod 34,and the rod extends slidably through the table top T and a spacing block35 thereon. At its lower end the rod 34 is screwed to a suitable clevis36 which is pivoted at 3'! to one end of a foot lever 38. The foot leveris pivoted intermediate its ends, as at 39, to a supporting post 49, andthe end of the lever opposite the pivot 31 has a foot-engaging portion 4I.

A spring 42, connected at one end to the post 49 and at the other end tothe free end of the lever 38, yieldingly holds the actuating rod 34 inits down position and the die blocks 32 in their inwardly collapsedpositions, as shown in Fig. 9. As indicated in. Fig. 9. the grease-proofliner G is easily placed, with its open end down, over the upper ends ofthe die blocks 32 in collapsed position in readiness to be expanded inits box-like shape.

The novel and improved method of making the subass mbly of the liner andbox parts for receiving the hot melted cheese consists in placinga linerG in inverted or downwardly open position over the collapsed die blocks32 as shown in Fig. 9, then depressingthe foot portion 4i of the lever33 to exnand'the die blocksand .the liner to the position of Fig. 10,and then the ie bl ks 32, there will be a lat ral y pro jectii foldedportion formed at each end of the liner, as indicated at 43, but thesewill be automatically folded alongside the ends of the liner wh n thebox membe I is telescoped thereover.

The operations of unfolding of the box it and telescoping it over theliner and flat sheet can be accomplished very rapidly in onesubstantially continuous motion by the, operator. Next, the lever 38 isreleased to collapse the die blocks to the position of Fig. 9, whereuponthe subassembly of the liner G, flat sheet i2, and box is can be.removed and inverted to the position of Fig. 12 in readiness to receivethe hot melted cheese.

After the cheese has solidified, the portions of the liner G projectingupwardly from the box H) are folded inwardly upon the top surface of themolded cheese, and the cover member ii is then telescoped over the upperportions is and 2E of the box Ell, into abutment with shoulders X,whereupon the package is completed, and is preferably inverted so thatthe flat sheet 52 is uppermost. The sheet 12 may be of transparent orsemi-transparent material, or have a transparent window formed therein,so that the smoothly molded surface of the contents of the package canbe readily viewed by the purchaser.

Accordingly, the novel method of assembling the liner, flat sheet andside wall member of the improved box provides for a considerable savingin time and space, in making the subassemblies for receiving the hotmelted cheese, because all of the parts required for the subassembly canbe supplied to the operator of the expanding mechanism in flat foldedcondition, and the operator can continuously and rapidly assemble allthe parts in readiness for receiving the hot cheese, without thenecessity of unfolding and partially assembling some of the parts as apreliminary step.

The novel improved foldable box is simple and inexpensive to make, andis quickly and easily assembled to provide a molding receptacle forprocessed cheese.

In the foregoing description, certain terms have been used for brevity,clearness and understanding, but no unnecessary limitations are to beimplied therefrom beyond the requirements of the prior art, because suchwords are used for descriptive purposes herein and are intended to bebroadly construed.

Moreover, the embodiment of the improved construction and methodillustrated and described herein is by way of example, and the scope ofthe present invention is not limited to the exact details ofconstruction or of the method.

Having now described the invention, the construction, the'operation anduse of a preferred embodiment thereof, and the advantageous new anduseful results obtained thereby; the new and useful constructions andmethods, and reasonable mechanical equivalents thereof obvious to thoseskilled in the art, are set forth in the appended claims.

I claim:

1. A col apsible box including side and end marginal flanges defining ar ctangular o ening at one end of the box, said flanges being foldablyconnected together at diagonally opposite corners and separated at theother corners, side wall portions attached to and folded upwardly fromopposite side marginal flanges, end wall portions attached to and foldedupwardly from said end marginal flanges, each of said side and end wallportions having panel members connected to their upper edges, said panelmembers folded on themselves accordion fashion and secured togetherforming adjoining flap portions including an outer flap, and the outerflaps being narrower than the contiguous flap portions and forming anouter shoulder extending around the box between the top and bottomthereof, and a cover on the box end opposite said marginal flanges andabutting said shoulder.

2. A collapsible box including side and end marginal flanges defining arectangular opening atone end of the box, said flanges being foldablyconnected together at diagonally opposite corners and separated at theother corners, side wall portions attached to and folded upwardly fromopposite side marginal flanges, end wall portions attached to and foldedupwardly from said end marginal flanges and having ends projectinglaterally beyond said end marginal flanges, each of said side and endwall portions having panel members connected to their upper edges, saidpanel members folded on themselves accordion fashion and securedtogether forming adjoining flap portions including an outer flap, theouter flaps being narrower than the contiguous flap portions and formingan outer shoulder extending around the box between the top and bottomthereof, and the ends of the said accordion folded end wall portionsbeing folded inwardly to form flaps under-lapping the side wallportions.

A collapsible box including side and end marginal flanges defining arectangular opening at one end of the box, said flanges being foldablyconnected together at diagonally opposite corners and separated at theother corners, side wall portions attached to and folded upwardly fromopposite side marginal flanges, end wall portions attached to and foldedupwardly from said end marginal flanges and having ends projectinglaterally beyond said end marginal flanges, each of said side and endwall portions having panel members connected to their upper edges, saidpanel members folded on themselves accordion fashion and securedtogether forming adjoining flap portions including an outer flap, theouter flaps being narrower than the contiguous flap portions and formingan outer shoulder extending around the box between the top and bottomthereof, the outer flags of said end wall portions being equal in lengthto the end marginal flanges, and the ends of said accordion folded endwall portions beyond said end wall outer flaps being folded inwardly toform flaps underlapping the side wall portions,

ALICE J. GROSSNIKLAUS.

REFERENCES 'CITED The following references are of record in the fllc ofthis patent:

UNITED STATES PATENTS

